JP3549523B2 - Acoustic matching layer, ultrasonic transducer and manufacturing method thereof - Google Patents

Description

【Technical field】
[0001]
The present invention relates to an acoustic matching layer used for matching acoustic impedance, an ultrasonic transducer for transmitting and receiving ultrasonic waves, a manufacturing method thereof, and an ultrasonic flowmeter using the same. is there.
[Background Art]
[0002]
FIG. 10 is a cross-sectional view schematically illustrating a configuration of a conventional ultrasonic generator (also referred to as a “piezoelectric vibrator”) 10. The ultrasonic generator 10 includes a case 1, a piezoelectric layer (vibration means) 2, and an acoustic impedance matching layer (matching means, hereinafter referred to as "acoustic matching layer"). The case 1 and the piezoelectric layer 2 are adhered by using an adhesive layer made of an adhesive (for example, epoxy-based). Case 1 and acoustic matching layer 100 are similarly connected using an adhesive. The piezoelectric layer vibrates at about 500 kHz, and the vibration is transmitted to the case 1 via an adhesive layer (not shown), and further transmitted to the acoustic matching layer 100 via the adhesive layer. The vibration of the acoustic matching layer 100 propagates as a sound wave to the gas existing in the space. Although not described for the sake of simplicity, a pair of electrodes (not shown) for polarizing the piezoelectric layer 2 in the thickness direction is provided on both sides of the piezoelectric layer 2, and the ultrasonic generator 10 Can mutually convert electrical energy and mechanical energy by the piezoelectric layer 2. The case 1 has an upper plate 1a forming a recess enclosing the piezoelectric layer 2 and a bottom plate 1b arranged so as to seal the space in the recess. The piezoelectric layer 2 is sealed in the recess. I have. One of the electrodes formed on the pair of main surfaces of the piezoelectric layer 2 is connected to the terminal 5a via the case 1, and the other is connected to the terminal 5b. Therefore, the case 1 is generally formed from a conductive metal.
[0003]
The role of the acoustic matching layer 100 is to efficiently propagate the vibration of the piezoelectric layer 2 to the gas. The acoustic impedance Z defined by the equation (1) differs greatly between the piezoelectric layer 2 and the gas depending on the sound velocity C and the density ρ of the substance.
[0004]
Z = ρ × C (1)
[0005]
The acoustic impedance Z1 of the piezoelectric material constituting the piezoelectric material layer 2 is 30 × 10⁶(Kg / s ・ m^Two), The acoustic impedance Z3 of a gas, for example, air is 4.28 × 10^Two(Kg / s ・ m^Two). The acoustic impedances of the piezoelectric body and the metal are almost equal. As described above, reflection occurs in the propagation of sound (vibration) on the boundary surfaces having different acoustic impedances, and as a result, the intensity of transmitted sound decreases. However, sound reflection can be reduced by inserting a substance having another acoustic impedance between two substances having different acoustic impedances.
[0006]
In general, it is possible to eliminate sound reflection by inserting a substance having an acoustic impedance Z2 satisfying the following expression (2) between the piezoelectric layer 2 and a space (a gas medium on the side from which sound waves are emitted). Are known.
[0007]
Z2 = (Z1 · Z3)^1/2... (2)
[0008]
The above Z1 = 30 × 10⁶(Kg / s ・ m^Two) And Z3 = 4.28 × 10^Two(Kg / s ・ m^Two), The value of Z2 is 0.11 × 10⁶(Kg / s ・ m^Two). A substance that satisfies this acoustic impedance is required to be a solid substance having a low density and a low sound velocity.
[0009]
In general, a gas ultrasonic generator using a piezoelectric material such as PZT also efficiently radiates ultrasonic waves generated by PZT to gas (air) as a propagation medium. Are provided. In an ultrasonic transducer that emits ultrasonic waves generated by PZT into the air, the acoustic impedance Z1 of air (gas) (about 400 kg / s · m)^Two) Is the acoustic impedance Z3 of PZT (solid) (about 30 × 10^Fivekg / s ・ m^Two), Which is an order of magnitude smaller than 100,000, so that the acoustic impedance of the acoustic matching layer is extremely important to efficiently radiate ultrasonic waves.
[0010]
Conventionally, as an acoustic matching layer provided on the vibration surface of a piezoelectric layer (also referred to as an “ultrasonic transducer”) made of piezoelectric ceramics such as PZT (lead zirconate titanate), as shown in FIG. Further, an acoustic matching layer 100 made of an epoxy resin 112 mixed with a glass balloon (a hollow fine glass sphere) 110 is known. The acoustic matching layer 100 has a small glass balloon 110 hardened with an epoxy resin 112 to reduce the density. Since the glass balloon 110 needs to be sufficiently smaller than the wavelength of the sound transmitted through the acoustic matching layer, a glass balloon having a diameter of 100 μm or less is used.
[0011]
The strength of sound transmitted through the acoustic matching layer 100 to the gas also depends on the thickness of the acoustic matching layer 100 (the distance over which sound waves propagate in the acoustic matching layer). The sound wave from the piezoelectric layer 2 is divided into a transmitted wave and a wave reflected at the boundary between the acoustic matching layer 100 and the gas. The reflected wave is reflected at the boundary surface between the acoustic matching layer 100 and the piezoelectric layer 2, and in this case, the wave has a phase inverted. A part of this wave becomes a wave transmitted at the boundary surface between the acoustic matching layer 100 and the gas. When the thickness t at which the transmittance T is maximized is determined by combining these waves, t = λ / 4.
[0012]
When the acoustic matching layer 100 including the glass balloon 110 is used, its sound speed is 2000 m / s. Therefore, when the frequency of the sound is 500 kHz, the wavelength λ of the sound propagating through the acoustic matching layer 100 is 4 mm. Therefore, the optimal value of the thickness t of the acoustic matching layer 100 is 1 mm.
[0013]
The theoretical formula for calculating the ultrasonic energy transmittance T from the ultrasonic transducer to the external propagation medium when the acoustic matching layer is provided on the vibration surface of the ultrasonic transducer is as follows. If it is set to an integral multiple, it is simplified and expressed as in the following equation (3).
[0014]
T = 4 ・ Z1 ・ Z3 ・ Z2^Two/ (Z1, Z3 + Z2^Two)^Two... (3)
[0015]
Considering the relationship between the ultrasonic energy transmittance T to the air and the acoustic impedance Z2 of the acoustic matching layer 100 in the acoustic matching layer 100 using a conventional glass balloon-containing epoxy resin, the acoustic impedance of the glass balloon-containing epoxy resin is approximately 1.2 × 10⁶kg / s ・ m^TwoAnd Z2^Two≒ 1.44 × 10¹²On the other hand, in the above example, Z1 · Z3 is equal to Z1 · Z3 = 400 × 1.2 × 10⁶= 4.8 × 10⁸And Z1, Z3≪Z2^TwoTherefore, the above equation (3) further satisfies T ≒ 4 · Z1 · Z3 / Z2.^TwoIt can be seen that the ultrasonic energy transmittance T is inversely proportional to the square of the acoustic impedance Z2 of the acoustic matching layer 100. That is, as the acoustic impedance Z2 of the acoustic matching layer 100 is smaller, the ultrasonic energy transmittance T is improved.
[0016]
FIG. 9 is a diagram schematically showing a configuration of an ultrasonic flowmeter provided with the above-described ultrasonic generator 10. Here, a pair of ultrasonic generators 10 are used as a pair of ultrasonic transducers 101 and 102.
[0017]
As shown in FIG. 9, the pair of ultrasonic generators 101 and 102 are arranged inside a pipe (tube wall) 52 that defines a gas flow path 51. If the ultrasonic transducer 101 or 102 breaks, gas leaks to the outside of the tube 52. Therefore, the material of the case (case 1 in FIG. 9) of the ultrasonic transducers 101 and 102 is a fragile material such as ceramic or resin. It is difficult to choose. Therefore, a metal material such as stainless steel or iron is used for the material of the case.
[0018]
Now, as shown in FIG. 9, it is assumed that the fluid is flowing in the flow path 51 at a velocity V in the direction indicated by the thick arrow along the flow path. Inside the tube wall 52, a pair of ultrasonic transducers 101 and 102 are installed facing each other. The ultrasonic transducers 101 and 102 are configured using a piezoelectric vibrator such as a piezoelectric ceramic as an electric energy / mechanical energy conversion element, and exhibit resonance characteristics like a piezoelectric buzzer and a piezoelectric oscillator. Here, for example, the ultrasonic transducer 101 is used as an ultrasonic transducer, and the ultrasonic transducer 102 is used as an ultrasonic transducer. Further, a driving circuit 54 for driving the ultrasonic transmitters / receivers 101 and 102 is connected to the ultrasonic transmitter 101 and the ultrasonic receiver 102 via a switching circuit 55 for switching between transmission and reception, and an ultrasonic pulse is supplied to the ultrasonic transmitter 101 and the ultrasonic receiver 102. A reception detection circuit 56 for detection, a timer 57 for measuring the propagation time of the ultrasonic pulse, a calculation unit 58 for calculating the flow rate from the output of the timer 57 by calculation, and a control unit 59 for outputting a control signal to the drive circuit 54 and the timer 57 are connected. Have been.
[0019]
The operation of the ultrasonic flow meter will be described below.
[0020]
First, when an AC voltage having a frequency near the resonance frequency is applied to the piezoelectric layer of the ultrasonic transmitter 101, the ultrasonic transmitter 101 transmits the ultrasonic wave through a propagation path indicated by L in FIG. The ultrasonic wave is radiated and received by the ultrasonic wave receiver 102 and converted into a voltage.
[0021]
Subsequently, on the contrary, the ultrasonic transducer 102 is used as an ultrasonic transducer, and the ultrasonic transducer 101 is used as an ultrasonic transducer. By applying an AC voltage having a frequency near the resonance frequency to the piezoelectric layer of the ultrasonic transmitter 102, the ultrasonic transmitter 102 transmits the ultrasonic wave through an external fluid through a propagation path indicated by L in FIG. The ultrasonic wave is radiated, and the ultrasonic wave receiver 101 receives the transmitted ultrasonic wave and converts it into a voltage. As described above, since the ultrasonic transmitters 101 and 102 serve as a receiver and a transmitter, they are generally called ultrasonic transmitters and receivers. The propagation direction of the ultrasonic wave in the propagation path L is an arrow (two-way) shown in the propagation path L.
[0022]
In FIG. 9, the flow velocity of the fluid flowing through the pipe 52 is V, the velocity of the ultrasonic wave in the fluid is C, and the angle between the direction in which the fluid flows (thick arrow) and the propagation direction of the ultrasonic pulse (arrow in L) is shown. θ. When the ultrasonic transmitter / receiver 101 is used as a transmitter and the ultrasonic transmitter / receiver 102 is used as a receiver, the time when an ultrasonic pulse emitted from the ultrasonic transmitter / receiver 101 reaches the ultrasonic transmitter / receiver 102 If the sing-around period is t1 and the sing-around frequency f1 is, the following equation (4) is established.
[0023]
f1 = 1 / t1 = (C + Vcos θ) / L (4)
[0024]
Conversely, if the sing-around period is t2 and the sing-around frequency f2 when the ultrasonic transducer 102 is used as a transmitter and the ultrasonic transducer 101 is used as a receiver, the following equation (5) is obtained. ) Holds.
[0025]
f2 = 1 / t2 = (C−Vcos θ) / L (5)
[0026]
Accordingly, the frequency difference Δf between the two sing-around frequencies is expressed by the following equation (6), and the flow velocity V of the fluid can be obtained from the distance L of the ultrasonic wave propagation path and the frequency difference Δf.
[0027]
Δf = f1−f2 = 2Vcosθ / L (6)
[0028]
That is, the flow velocity V of the fluid can be obtained from the distance L of the ultrasonic wave propagation path and the frequency difference Δf, and the flow rate can be checked from the flow velocity V.
[0029]
In the conventional ultrasonic generator, in order to keep the acoustic impedance of the acoustic matching layer low, the acoustic matching layer is formed using a material having a low density, for example, a material obtained by solidifying a glass balloon or a plastic balloon with a resin material or the like. Was. Further, the acoustic matching layer has been formed by a method of thermally compressing a glass balloon or a method of foaming a molten material. These methods are disclosed in, for example, Japanese Patent No. 2559144.
[0030]
The conventional acoustic matching layer is made by mixing a glass balloon having a smaller particle size than the ultrasonic wave into the epoxy resin (that is, the air gap having a small acoustic impedance that does not irregularly reflect the ultrasonic wave in the epoxy resin). Since the acoustic impedance Z2 of the acoustic matching layer is reduced (by scattering), the mixing ratio of the glass balloon to the epoxy resin may be increased to further reduce the acoustic impedance. When the ratio is increased, the viscosity of the epoxy resin agent containing the glass balloon increases, and it becomes difficult to uniformly mix the glass balloon and the epoxy resin agent.Therefore, to increase the mixing ratio of the glass balloon to the epoxy resin agent, There are certain limitations. Therefore, it is difficult to produce an acoustic matching layer having a lower acoustic impedance with a glass balloon-containing epoxy resin.
[0031]
The acoustic impedance of the conventional acoustic matching layer made of epoxy resin containing a glass balloon is about 1.2 × 10⁶kg / s ・ m^TwoAnd about 2/3 of the acoustic impedance of the acoustic matching layer made of only epoxy resin, and the ultrasonic energy transmittance T is 9/4 as compared with that using the acoustic matching layer made of only epoxy resin. It is improved twice.
[0032]
However, even when the ultrasonic energy transmittance T in the case of using the acoustic matching layer made of the epoxy resin filled with the glass glass balloon from the above equation (3) is calculated, it is understood that T ≒ 3%, which is not sufficient.
[0033]
The acoustic matching layer used in the conventional ultrasonic transducer used in the ultrasonic flowmeter is formed by, for example, thermally compressing a glass balloon or foaming a molten material as described above. Had been. For this reason, the medium is likely to be non-homogeneous due to breakage of the glass sphere due to pressure, separation due to insufficient pressure, foaming of the exfoliated molten material, etc., causing variations in characteristics in the acoustic matching layer, which causes variations in device precision. There was a problem that it was.
[0034]
Further, in the above-described conventional process of manufacturing an acoustic matching layer made of epoxy resin containing glass balloons, cutting and / or surface polishing is performed so that a cured product of the epoxy resin containing glass balloons has a desired size and / or thickness. Because of the mechanical processing such as the above, there is a problem that the thickness of the acoustic matching layer deviates from a preferable value, or the thickness becomes uneven, or irregularities are formed on the surface. As a result, sufficient performance could not be obtained.
[0035]
On the other hand, the applicant of the present application discloses a case in which a conventional glass balloon-filled epoxy resin is used in Japanese Patent Application No. 2001-56501 (filing date: February 28, 2001) by forming an acoustic matching layer using a dry gel. For example, it describes that variations in characteristics in the acoustic matching layer can be reduced.
[0036]
However, in order to further improve the performance of, for example, an ultrasonic flowmeter, it is desired to further reduce the variation in the characteristics of the acoustic matching layer using the dried gel.
[0037]
According to the results examined by the inventor, the variation in the thickness of the acoustic matching layer is smaller than in the past, but also occurs when a dry gel is used. It was also found that when a dry gel was formed by drying a wet gel, there was a variation in characteristics due to unevenness in the drying process.
DISCLOSURE OF THE INVENTION
[Problems to be solved by the invention]
[0038]
The present invention has been made in view of the above problems, and a main object thereof is to provide an acoustic matching layer in which variation in characteristics is reduced as compared with the related art, and an ultrasonic wave including such an acoustic matching layer. It is an object of the present invention to provide a transducer and an ultrasonic flowmeter. Another object of the present invention is to provide a method for manufacturing such an acoustic matching layer and an ultrasonic transducer.
[Means for Solving the Problems]
[0039]
The acoustic matching layer according to the first aspect of the present invention comprises a dry gel powder.
[0040]
In one embodiment, the density of the dried gel is 500 kg / m^ThreeOr less, and the average pore diameter is 100 nm or less.
[0041]
In one embodiment, the average particle size of the powder of the dried gel is in a range of 1 μm or more and 100 μm or less.
[0042]
In one embodiment, the solid skeleton of the dried gel includes an inorganic oxide. Preferably, the solid skeleton is hydrophobized.
[0043]
In one embodiment, the inorganic oxide is silicon oxide or aluminum oxide.
[0044]
In one embodiment, the powder of the heat-binding polymer contains 40% by mass or less of the whole.
[0045]
In one embodiment, the thermal binding polymer powder has an average particle diameter in a range of 0.1 μm or more and 50 μm or less.
[0046]
In one embodiment, the acoustic impedance is 5 × 10^Fourkg / s ・ m^TwoMore than 20 × 10^Fourkg / s ・ m^TwoIt is in the following range.
[0047]
In one embodiment, the temperature change rate of the acoustic impedance in the range of 25 ° C. or more and 70 ° C. or less is −0.04% / ° C. or less (absolute value is 0.04% / ° C. or less).
[0048]
In one embodiment, the thickness of the acoustic matching layer is about one quarter of the wavelength λ of the sound wave propagating in the acoustic matching layer.
[0049]
An ultrasonic transducer according to a first aspect of the present invention includes a piezoelectric layer and any one of the above acoustic matching layers provided on the piezoelectric layer.
[0050]
In one embodiment, the acoustic matching layer is directly bonded on the piezoelectric layer.
[0051]
In one embodiment, the piezoelectric device further includes a case having an upper plate forming a concave portion including the piezoelectric layer, and a bottom plate arranged to seal a space in the concave portion, wherein the piezoelectric layer is formed of the case. The acoustic matching layer is directly bonded to the upper surface of the upper plate so as to face the piezoelectric layer via the upper plate.
[0052]
An ultrasonic flowmeter according to a first aspect of the present invention includes a flow measurement unit through which a fluid to be measured flows, a pair of ultrasonic transducers provided in the flow measurement unit for transmitting and receiving ultrasonic signals, and the ultrasonic transmission and reception unit. A measuring circuit for measuring an ultrasonic propagation time between wave devices, and an ultrasonic flowmeter including a flow rate calculating circuit for calculating a flow rate based on a signal from the measuring circuit, wherein the pair of ultrasonic transducers Are constituted by the ultrasonic transducer according to any of the above.
[0053]
The method for manufacturing an acoustic matching layer according to the first aspect of the present invention includes a step of preparing a mixed powder of a powder of a dry gel and a powder of a heat-binding polymer, and a step of press-molding the mixed powder. Include.
[0054]
In one embodiment, the step of preparing the mixed powder includes the step of preparing the dry gel, the step of preparing a powder of the heat binding polymer, and the step of preparing the dry gel and the heat binding polymer. Pulverizing while mixing with the powder.
[0055]
In one embodiment, the step of press-molding the mixed powder includes a step of heating the mixed powder.
[0056]
In one embodiment, the step of press-molding the mixed powder includes a step of controlling a thickness of a compact of the mixed powder obtained by the pressure molding to a predetermined thickness.
[0057]
In one embodiment, the step of press-molding the mixed powder includes a step of supplying a predetermined amount of the mixed powder on a lower molding surface, and a step of forming the mixed powder supplied on the lower molding surface. Planarizing the upper surface of the layer.
[0058]
A method for manufacturing an ultrasonic transducer according to a first aspect of the present invention is a method for manufacturing an ultrasonic transducer including a piezoelectric layer and an acoustic matching layer provided on the piezoelectric layer. Forming the acoustic matching layer by any one of the above-described manufacturing methods.
[0059]
In one embodiment, the acoustic matching layer is directly bonded on the piezoelectric layer.
[0060]
In one embodiment, the ultrasonic transmission / receptionvesselFurther includes a case having an upper plate forming a recess enclosing the piezoelectric layer, and a bottom plate arranged to seal a space in the recess, wherein the acoustic matching layer is provided on the case. Directly bonded to the top surface of the board.
[0061]
A method for manufacturing an ultrasonic transducer according to a second aspect of the present invention is a method for manufacturing an ultrasonic transducer including a piezoelectric layer and an acoustic matching layer provided on the piezoelectric layer. The process of forming the acoustic matching layer includes: (a) a step of preparing a gel raw material liquid; and (b) providing a thickness regulating member having a predetermined height on a surface on which the acoustic matching layer is formed. (C) applying the gel raw material liquid on the surface; and (d) adjusting the thickness of the liquid layer formed by the gel raw material liquid applied on the surface to the height of the thickness regulating member. (E) a solidification step of forming a wet gel from the gel raw material liquid, and (f) a drying step of forming a dry gel by removing a solvent contained in the wet gel. Include. According to the ultrasonic transducer manufacturing method of the second aspect, the thickness of the acoustic matching layer is controlled to a predetermined thickness, so that variations in characteristics due to variations in thickness are suppressed.
[0062]
In one embodiment, the acoustic matching layer has a first acoustic matching layer disposed on the piezoelectric layer side, and a second acoustic matching layer provided on the first acoustic matching layer. The process of forming the acoustic matching layer includes the above steps (a) to (f).
[0063]
In one embodiment, the thickness regulating sectionLumberIs about one quarter of the wavelength λ of the sound wave propagating in the corresponding acoustic matching layer.
[0064]
The dry gel used for the acoustic matching layer according to the present invention may be a dry gel having an inorganic oxide as a solid skeleton or a dry gel having an organic polymer as a solid skeleton.
【The invention's effect】
[0065]
Since the acoustic matching layer according to the first aspect of the present invention includes the powder of the dried gel, the variation in the characteristics due to the unevenness of the drying process of the wet gel is suppressed.
[0066]
According to the second aspect of the present invention, in the process of manufacturing the acoustic matching layer, the thickness of the acoustic matching layer is controlled. Therefore, variations in the characteristics due to variations in the thickness of the acoustic matching layer and irregularities on the surface are suppressed.
[0067]
Further, when a dry gel of an inorganic oxide or an organic polymer is formed, the OH groups on the surface of the piezoelectric body or the surface of the container (case) react with the components of the raw material to be chemically bonded and adhered. There is also obtained an excellent effect that a so-called ultrasonic transducer without an adhesive layer can be obtained.
[0068]
Further, by forming an acoustic matching layer made of a dried gel of an inorganic oxide or an organic polymer with a high thickness accuracy on the conventional acoustic matching layer, a more highly sensitive ultrasonic transducer can be obtained. Can be
BEST MODE FOR CARRYING OUT THE INVENTION
[0069]
The acoustic matching layer according to the first aspect of the present invention includes a dry gel powder. By forming the acoustic matching layer using the powder of the dry gel, variation in characteristics due to unevenness in the drying process of the wet gel is suppressed.
[0070]
FIGS. 1A and 1B schematically show the structure of an acoustic production layer according to an embodiment according to the first aspect of the present invention.
[0071]
The acoustic matching layer 3A shown in FIG. 1A is composed of a powder of a dry gel (hereinafter, also referred to as “powder dry gel”) 3a and an additive 3b.
[0072]
The `` dry gel '' in the present specification is a porous body formed by a sol-gel reaction, and a solid skeleton solidified by a reaction of a gel raw material liquid is dried through a wet gel including a solvent. It is formed by removing the solvent.
[0073]
In order to obtain a dried gel, the method of drying after removing the solvent from the wet gel is a drying method under special conditions such as supercritical drying or freeze drying, or a normal drying method such as heating drying, drying under reduced pressure, and drying by standing naturally. A method can be used.
[0074]
Supercritical drying is a method in which the solvent is removed in a supercritical state at a temperature and pressure above its critical point, and there is no gas-liquid interface and no drying stress is applied to the solid skeleton of the gel, so it shrinks or shrinks. A very low-density dried gel can be obtained without performing. On the other hand, the dried gel obtained by supercritical drying may be affected by stress in the use environment, for example, dew condensation, heat stress, chemical stress, mechanical stress, and the like.
[0075]
On the other hand, a dried gel obtained by a normal drying method has a characteristic of being highly durable even in a subsequent use environment stress because it can withstand drying stress. In order to obtain a low-density dry gel by such a normal drying method, it is necessary to make the solid skeleton part capable of withstanding stress in a wet gel stage before drying. For example, aging the solid skeleton to increase its strength, applying temperature conditions or a polyfunctional hydrophobizing agent that is easy to polymerize to reinforce the solid skeleton when hydrophobizing, or reducing the size of the pores It can be realized by controlling. In particular, when measuring the flow rate of a gas, it may be used in various environments, so it is preferable to obtain the acoustic matching layer with a dried gel prepared by a normal drying method. In addition, when a normal drying method is applied, since the process is not a high-pressure process such as supercritical drying, there are advantages such as simplification of equipment and easy handling.
[0076]
The dried gel obtained by the above method is a nanoporous body in which continuous pores having an average pore diameter in a range of 1 nm to 100 nm are formed by a solid skeleton having a nanometer size. Therefore, the density is 500 kg / m^ThreeOr less, preferably 400 kg / m^ThreeIn the following low-density conditions, the speed of sound propagating through the solid portion of the dried gel forming the unique network skeleton is extremely low, and the speed of sound propagating through the gas portion of the porous body through the pores is extremely low. It has the property of becoming smaller. Therefore, it has a characteristic that a very low value of 500 m / s or less is exhibited as a sound velocity, and a low acoustic impedance can be obtained.
[0077]
In the nanometer-sized pore portion, the pore size is less than or equal to the mean free path of the gas molecules, and the pressure loss of the gas is large. It also has the characteristic that it can be radiated by pressure.
[0078]
The average particle size of the dried powder gel is preferably 1 μm or more and 100 μm or less. If it is smaller than this lower limit, the number of pores in the powder will decrease and the characteristic of dried gelWhatThe effect is reduced, and the required amount of additives for molding increases, so that it may be difficult to obtain a low-density acoustic matching layer. If the average particle size of the powder dried gel is larger than the upper limit, it is difficult to control the thickness of the acoustic matching layer, and it is difficult to form an acoustic matching layer having sufficient thickness uniformity and surface flatness. There is.
[0079]
The solid skeleton of the dried gel may be an inorganic oxide or an organic polymer. Further, it is preferable that the solid skeleton is made hydrophobic. By making the surface hydrophobic, for example, when moisture or impurities are present in the gas to be measured, the gas or the impurities can be made less susceptible to the adsorption or adhesion of the moisture or impurities, so that a more reliable acoustic matching layer can be obtained.
[0080]
Hydrophobicization of the solid skeleton of the dried gel of inorganic oxide is performed using a surface treatment agent such as a silane coupling agent. Examples of the surface treatment agent include halogen-based silane treatment agents such as trimethylchlorosilane, dimethyldichlorosilane, methyltrichlorosilane, and ethyltrichlorosilane, and alkoxy-based agents such as trimethylmethoxysilane, trimethylethoxysilane, dimethyldimethoxysilane, and methyltriethoxysilane. Silane treating agents, silicone-based silane treating agents such as hexamethyldisiloxane and dimethylsiloxane oligomer, amine-based silane treating agents such as hexamethyldisilazane, alcohol-based treating agents such as propyl alcohol, butyl alcohol, hexyl alcohol, octanol, decanol Etc. can be used.
[0081]
Further, by using a fluorinated treating agent in which a part or all of the hydrogen of the alkyl group of these treating agents is replaced by fluorine, in addition to hydrophobicity (water repellency), further excellent oil repellency, antifouling property, etc. The effect obtained is as follows.
[0082]
As the solid skeleton of the dried gel of the inorganic oxide, one containing at least silicon oxide (silica) or aluminum oxide (alumina) can be suitably used. The solid skeleton of the dried gel of the organic polymer can be made of a general thermosetting resin or thermoplastic resin. For example, polyurethane, polyurea, phenol cured resin, polyacrylamide, polymethyl methacrylate, and the like can be applied.
[0083]
In particular, a dried gel having a solid skeleton of an inorganic oxide has excellent humidity resistance and chemical resistance, and also has excellent temperature characteristics of acoustic impedance. That is, when a dry gel of an inorganic oxide is used, the temperature change rate of the acoustic impedance within the range of 25 ° C. or more and 70 ° C. or less is −0.04% / ° C. or less (the absolute value is 0.04% / ° C. or less). Meaning) acoustic matching layer can be obtained. In contrast, when a conventional epoxy / glass balloon system or organic polymer gel is used, it is difficult to make the absolute value of the temperature change rate of the acoustic impedance 0.04% / ° C. or less.
[0084]
When the temperature change rate of the acoustic impedance is small, for example, when used in an ultrasonic flowmeter described later, high measurement accuracy can be obtained over a wide temperature range.
[0085]
As the additive (binder) 3b for bonding the powder dried gels 3a to each other and improving the mechanical strength of the acoustic matching layer 3A, a polymer powder having thermal binding properties can be suitably used. When a liquid material is used, it penetrates into the pores of the dried gel, changing the acoustic characteristics and lowering the moldability.underTherefore, it is preferable to use a solid material, particularly a powder.
[0086]
Here, the term “thermally binding polymer” refers to a polymer that is solid at room temperature, melts or softens by heating, and then solidifies. Thermo-binding polymers are not only general thermoplastic resins (for example, engineering plastics such as polyethylene and polypropylene), but also, for example, thermosetting resins that are solid at room temperature, soften once by heating, and then cross-link and harden. (For example, phenol resin, epoxy resin, urethane resin) can be used. When the thermosetting resin contains the main agent and the curing agent, each may be added as separate powders. Of course, a mixture of a thermoplastic resin and a thermosetting resin may be used. The melting (softening) temperature of the heat-binding polymer powder is preferably in the range of 80 ° C to 250 ° C.
[0087]
When a heat-binding polymer is used as an additive, it typically melts (softens) when a mixed powder of the powdery dry gel 3a and the additive is pressed while being heated, as described later. When the additive solidifies with cooling and / or cross-links and hardens, the additive becomes the same as the powder dry gel 3a.ChiefPlay a role in joining.
[0088]
The average particle diameter of the heat-binding polymer powder is preferably 0.1 μm or more and 50 μm or less. If it is smaller than the lower limit, the particle diameter becomes close to the pore diameter of the powdery dried gel, so that the binding property may be reduced or the moldability may be reduced. On the other hand, if it is larger than the upper limit, the addition amount required for molding increases, so that it may be difficult to obtain a low-density acoustic matching layer.
[0089]
Further, the addition amount of the heat binding polymer powder is preferably 40% by mass or less of the whole. If the total amount exceeds 40% by mass, the density at the time of molding may increase. In order to obtain sufficient mechanical strength, for example, it is preferable to add 5% by mass or more of the whole.
[0090]
In order to strengthen the bonding between the above-mentioned additive (sometimes referred to as “additive A”) and the powdered dry gel, as shown in FIG. 1B, as shown in the acoustic matching layer 3B schematically shown in FIG. Inorganic fibers (eg, glass wool or organic fibers) and whiskers may be further added (sometimes referred to as “additive B”). In the acoustic matching layer 3B shown in FIG. 1B, the additive 3b is the same heat-binding polymer powder as described above, and the additive 3c is a short fiber. The preferred diameter range of the short fibers is about the same as the average particle diameter of the above-mentioned heat-binding polymer powder, and the length of the fibers is preferably about several μm to several mm.
[0091]
The addition amount of the two types of additives is preferably 40% by mass or less based on the whole, and the mixing ratio is appropriately set as necessary.
[0092]
The acoustic matching layer using the powdered dry gel of the present invention has an additional advantage that the acoustic impedance can be easily adjusted. For example, by mixing a plurality of types of powdered dry gels having different densities from each other, the acoustic impedance can be adjusted. Further, the acoustic impedance can be adjusted by adjusting the amount of the above-mentioned additive A (additive B if necessary). Of course, the amount of the additives A and B is preferably within the above range in consideration of moldability and the like.
[0093]
Preferably, the thickness of each of the acoustic matching layers 3A and 3B is about の of the wavelength λ of the sound wave propagating in each acoustic matching layer.
[0094]
A method of manufacturing an ultrasonic transducer according to an embodiment according to the second aspect of the present invention is a method of manufacturing an ultrasonic transducer including a piezoelectric layer and an acoustic matching layer provided on the piezoelectric layer. The process of forming the acoustic matching layer includes (a) a step of preparing a gel raw material liquid, and (b) providing a thickness regulating member having a predetermined height on a surface on which the acoustic matching layer is formed. A step of applying the gel raw material liquid on the surface (c), and the thickness of the liquid layer formed by the gel raw material liquid applied on the surface (d) is substantially equal to the height of the thickness regulating member. And (e) a solidifying step of forming a wet gel from the gel raw material liquid, and (f) a drying step of forming a dry gel by removing a solvent contained in the wet gel. Therefore, since the thickness of the acoustic matching layer is controlled to a predetermined thickness, variation in characteristics due to variation in thickness is suppressed.
[0095]
Needless to say, by forming the acoustic matching layer using the above-mentioned powdered dry gel, variation in characteristics is further suppressed. In addition, when a dry powder gel is used, a dry powder gel can be prepared in advance, so that there is an advantage that the productivity of the ultrasonic transducer can be improved. That is, in the above-described ultrasonic transducer manufacturing process, the step of solidifying the gel raw material liquid to obtain a wet gel and the step of drying the wet gel can be performed in advance, so that the manufacturing of the ultrasonic transducer is performed. Throughput can be improved.
[0096]
Hereinafter, more specific embodiments of the present invention will be described. The basic structure of the ultrasonic transducer, except for the acoustic matching layer and the joining structure thereof, is the same as that of the conventional ultrasonic transducer 10 shown in FIG.
[0097]
Next, an embodiment of a method of manufacturing the acoustic matching layer 100 shown in FIG. 8 and attaching the same to the piezoelectric layer 2 or the case 1 to manufacture an ultrasonic transducer using FIGS. Will be described.
[0098]
(First Embodiment)
FIG. 2 is a process diagram illustrating a method for manufacturing an ultrasonic transducer having an acoustic matching layer according to the first embodiment of the present invention. This drawing will be described in the order of Step 1 to Step 4.
[0099]
Step 1: low-density dry gel made of porous material (density: about 200 kg / m^Three~ 400kg / m^Three) And about 10% by mass (based on the whole) of additive A and additive B. The dried gel prepared here does not necessarily need to be a powder. It may be in a block shape. The dry gel is, for example, a silica dry gel having an average pore diameter of 20 nm, the additive A is a polypropylene powder, and the additive B is a glass wool having a fiber diameter of about 10 μm.
[0100]
Step 2: These are placed in the same container, mixed and pulverized to produce a fine powder. It is typically performed using a mill. Here, the pulverization conditions are adjusted so that a powdery dry gel having the desired average particle size described above is obtained. Moreover, you may classify as needed. Of course, the step of pulverizing the dried gel and the step of mixing may be performed separately.
[0101]
Step 3: A desired amount of a mixed powder composed of a low-density powder dry gel, an additive A and an additive B is weighed and supplied onto the case 1 to which the piezoelectric layer 2 is adhered.
[0102]
Step 4: A thickness regulating member (control unit) 4 is installed from above to control the thickness of the compact of the mixed powder 3 so as to have a thickness of about λ / 4, and is heated and pressed. Mold. Then, the additive A is once melted and then cooled and solidified, whereby the low-density powder dry gel is fixed. In addition, the additive B is the same as the powder dry gel when the additive A is used.ChiefThe bond strength offurtherAnd a hard acoustic matching layer can be obtained.
[0103]
Further, by doing so, the acoustic matching layer 3 composed of the dry powder gel, the additive A, and the additive B can be bonded to the case 1 without using an adhesive.
[0104]
Of course, it is preferable to control the thickness of the acoustic matching layer in the process of forming the acoustic matching layer using the powdered dry gel as described above. Small acoustic matching can be obtained. Also, by using the above-described method, the acoustic matching layer 3 can be directly bonded to the case 1 without using an adhesive. (For example, stability against a gas containing sulfur S) is improved. However, depending on the application, the acoustic matching layer formed in advance may be joined to the case using an adhesive.
[0105]
Further, at this time, the piezoelectric body may be simultaneously bonded at the time of pressurization and heat molding for forming an acoustic matching layer made of powdery dried gel.
[0106]
According to this embodiment, a low-density, hard, low acoustic impedance, high-thickness, and high-accuracy acoustic matching layer can be formed. An ultrasonic transducer can be obtained.
[0107]
Here, the example using the case 1 having the upper plate 1a forming the concave portion enclosing the piezoelectric layer 2 and the bottom plate 1b arranged so as to seal the space in the concave portion is shown. Not limited to For example, the acoustic matching layer 3 directly joined to the piezoelectric layer 2 may be sealed in a cylindrical case.
[0108]
(Second embodiment)
FIG. 3 is a process chart illustrating a method for manufacturing an ultrasonic transducer having an acoustic matching layer according to the second embodiment of the present invention. This figure will be described in the order of Step 1 to Step 5.
[0109]
Step 1: Prepare a low-density dry powder gel made of a porous material and about 10% by mass of additive A. Here, as the additive A, a powder of an epoxy resin (main agent) (additive A1) and a powder of a polyamide resin (additive A2) serving as a curing agent for the epoxy resin are used.
[0110]
Step 2: These are placed in the same container, mixed and pulverized to produce a fine powder.
[0111]
Step 3: A desired amount of a mixed powder composed of a low-density powder dry gel, an additive A1, and an additive A2 is weighed and supplied onto the case 1 to which the piezoelectric layer 2 is adhered.
[0112]
The process up to this step can be performed in the same manner as in the first embodiment.
[0113]
Step 4: The case 1 into which the mixed powder 3 has been charged is vibrated by a shaker or the like to flatten the layer of the mixed powder 3 charged.
[0114]
Step 5: A thickness regulating member (control section) 4 is installed from above to control the thickness of the compact of the mixed powder 3 so as to have a thickness of about λ / 4, and is heated and pressed. Mold. Then, the additive A1 and the additive A2 undergo a cross-linking and curing reaction, the low-density powder dry gel is fixed, and a hard (excellent mechanical strength) acoustic matching layer can be obtained.
[0115]
By doing so, the powder dry gel and the additive A1And additivesA2Can be bonded to the case 1 without using an adhesive.
[0116]
Further, at this time, the piezoelectric body may be simultaneously bonded at the time of pressurization and heat molding for forming an acoustic matching layer made of powdery dried gel.
[0117]
According to the present embodiment, the method further includes a step of flattening the upper surface of the layer of the mixed powder before forming the formed body of the mixed powder by pressure molding. Also, the variation in characteristics is small.
[0118]
(Third embodiment)
FIG. 4 is a process diagram illustrating a method for manufacturing an ultrasonic transducer having an acoustic matching layer according to the third embodiment of the present invention. This drawing will be described in the order of Step 1 to Step 4.
[0119]
Step 1: The piezoelectric layer 2 is bonded to the case 1. Bonding can be performed using a known adhesive or the like.
[0120]
Step 2: An O- layer made of an organic film or the like as a thickness regulating member (control section) for controlling the thickness of the acoustic matching layer on the case 1 so that the thickness becomes about λ / 4. The ring 31 is set.
[0121]
Step 3: On the case 1 on which the O-ring 31 is installed, an aqueous solution of silicic acid having a pH of 9 to 10 is dropped as a sol solution to adjust the pH of the aqueous solution of silicic acid to 5.5. Then, the wet gel 33 is formed by pressing the plate 32 from above. When the aqueous solution of silicic acid gels, the OH groups on the surface of the case 1 react with the silanol groups of the raw material to form a chemical bond, forming a wet gel film on the surface of the case 1.
[0122]
Step 4: The obtained wet gel is hydrophobized with an acetone solution of trimethylchlorosilane (TMSC), and a dehydration treatment is performed. After the solvent is replaced with hexane, drying is performed in a container maintained at 100 ° C., to form a silica dry gel film 34 of silicon oxide. Then, the low-density dry gel film is fixed, and the acoustic matching layer can be obtained.
[0123]
By doing so, the acoustic matching layer made of the dried gel can be adhered to the case 1 without using an adhesive.
[0124]
At this time, the piezoelectric body may be bonded after forming the acoustic matching layer made of dry gel.
[0125]
As described above, a low-density, low-acoustic-impedance, high-thickness-accuracy, high-accuracy acoustic matching layer can be formed, and by using this, a highly-sensitive, highly-reliable, stable ultrasonic transducer is used. Can be obtained.
[0126]
(Fourth embodiment)
FIG. 5 is a process chart illustrating a method for manufacturing an ultrasonic transducer having an acoustic matching layer according to the fourth embodiment of the present invention. This drawing will be described in the order of Step 1 to Step 4.
[0127]
Step 1: The piezoelectric layer 2 is bonded to the case 1.
[0128]
Step 2: A wire 41 made of metal or the like is provided on the case 1 as a thickness regulating member (control section) to control the thickness of the acoustic matching layer so as to have a thickness of about λ / 4. Install.
[0129]
Step 3: An aqueous solution of silicic acid having a pH of 9 to 10 is dropped as a sol solution onto the case 1 on which the wire 41 is installed, and the pH of the aqueous solution of silicic acid is adjusted to 5.5. Then, the wet gel 33 is formed by pressing the plate 32 from above. When the aqueous solution of silicic acid gels, the OH groups on the surface of the case 1 react with the silanol groups of the raw material to form a chemical bond, forming a wet gel film on the surface of the case 1.
[0130]
Step 4: The obtained wet gel is hydrophobized with an acetone solution of trimethylchlorosilane (TMSC), and a dehydration treatment is performed. After the solvent is replaced with hexane, drying is performed in a container maintained at 100 ° C. to form a dried silica gel film 34 of silicon oxide. Then, the low-density dry gel film is fixed, and the acoustic matching layer can be obtained.
[0131]
By doing so, the acoustic matching layer made of the dried gel can be adhered to the case 1 without using an adhesive.
[0132]
At this time, the piezoelectric body may be adhered after forming the acoustic matching layer made of dry gel.
[0133]
As described above, a low-density, low-acoustic-impedance, high-thickness-accuracy, high-accuracy acoustic matching layer can be formed, and by using this, a highly-sensitive, highly-reliable, stable ultrasonic transducer is used. Can be obtained.
[0134]
(Fifth embodiment)
FIG. 6 is a process chart illustrating a method for manufacturing an ultrasonic transducer having an acoustic matching layer according to the fifth embodiment of the present invention. This drawing will be described in the order of Step 1 to Step 4.
[0135]
Step 1: The piezoelectric layer 2 is bonded to the case 1.
[0136]
Step 2: A bead 51 is provided on the case 1 as a thickness control unit in order to control the thickness of the acoustic matching layer to have a thickness of λ / 4. As the beads 51, for example, beads that are not melted or deteriorated in a subsequent process may be used, and beads formed of an inorganic material such as glass or an organic material such as a cross-linked polymer can be used. .
[0137]
Step 3: An aqueous solution of silicic acid having a pH of 9 to 10 is dropped as a sol solution onto the case 1 on which the beads 51 are installed, and the pH of the aqueous solution of silicic acid is adjusted to 5.5. Then, the wet gel 33 is formed by pressing the plate 32 from above. When the aqueous solution of silicic acid gels, the OH groups on the surface of the case 1 react with the silanol groups of the raw material to form a chemical bond, forming a wet gel film on the surface of the case 1.
[0138]
Step 4: The obtained wet gel is hydrophobized with an acetone solution of dimethyldimethoxysilane, and dehydrated. After the solvent is replaced with hexane, drying is performed in a container maintained at 100 ° C., to form a silica dry gel film 34 of silicon oxide. Then, the low-density dry gel film is fixed, and the acoustic matching layer can be obtained.
[0139]
By doing so, the acoustic matching layer made of the dried gel can be adhered to the case 1 without using an adhesive.
[0140]
At this time, the piezoelectric body may be adhered after forming the acoustic matching layer made of dry gel.
[0141]
As described above, a low-density, low-acoustic-impedance, high-thickness-accuracy, high-accuracy acoustic matching layer can be formed, and by using this, a highly-sensitive, highly-reliable, stable ultrasonic transducer is used. Can be obtained.
[0142]
(Sixth embodiment)
FIG. 7 is a process diagram illustrating a method for manufacturing an ultrasonic transducer including an acoustic matching layer according to the sixth embodiment of the present invention. This drawing will be described in the order of Step 1 to Step 4.
[0143]
Step 1: The piezoelectric layer 2 and the ceramic 61 are bonded to the case 1. The ceramic 61 functions as a first acoustic matching layer. For example, as the ceramic 61, silica, alumina, zirconia, or the like can be preferably used.
[0144]
Step 2: The thickness of the acoustic matching layer on the periphery of the ceramic 61 on the case 1 is controlled so that the thickness of the acoustic matching layer becomes approximately λ / 4. An O-ring 31 made of a film or the like is provided.
[0145]
Step 3: On the ceramic 61 on which the O-ring 31 is installed, an aqueous solution of silicic acid having a pH of 9 to 10 is dropped as a sol solution to adjust the pH of the aqueous solution of silicic acid to 5.5. Then, the wet gel 33 is formed by pressing the plate 32 from above. When the aqueous solution of silicic acid gels, the OH groups on the surface of the case 1 react with the silanol groups of the raw material to form a chemical bond, forming a wet gel film on the surface of the case 1.
[0146]
Step 4: The obtained wet gel is hydrophobized with an acetone solution of trimethylchlorosilane (TMSC), and a dehydration treatment is performed. Further, it is dried in a container maintained at 50 ° C. to form a silica dry gel film 34 of silicon oxide. Then, the low-density dry gel film is fixed, and the acoustic matching layer can be obtained. After that, the piezoelectric vibrator 10 is completed by assembling the bottom plate (cover plate) of the case 1 and the drive terminals.
[0147]
By doing so, the acoustic matching layer made of the dried gel can be adhered to the ceramic 61 without using an adhesive, and high sensitivity can be achieved by the two-layer acoustic matching layer.
[0148]
At this time, the piezoelectric body may be adhered after forming the acoustic matching layer made of dry gel.
[0149]
When a two-layered acoustic matching layer (the first acoustic matching layer is on the piezoelectric layer side and the second acoustic matching layer is on the gas side), the acoustic impedance Zb of the second acoustic matching layer is equal to the first acoustic matching layer. Is preferably smaller than the acoustic impedance Za. The density of the first acoustic matching layer is 400 kg / m.^ThreeMore than 1500kg / m^ThreeWithin the following range, and the density of the second acoustic matching layer is 50 kg / m.^ThreeMore than 500kg / m^ThreeIt is preferable that the density is within the following range and the density of the second acoustic matching layer is lower than the density of the first acoustic matching layer. For example, the density of the first acoustic matching layer is 400 kg / m^Three800 kg / m^ThreeWithin the following range, and the density of the second acoustic matching layer is 50 kg / m.^ThreeMore than 400kg / m^ThreeIt is in the following range.
[0150]
The first acoustic matching layer can be formed using a known material such as ceramics exemplified here, a fibrous body of an inorganic material, a sintered porous body, a material obtained by solidifying a glass balloon or a plastic balloon with a resin matrix. . On the other hand, by using a dried gel, a second acoustic matching layer satisfying the above conditions can be obtained.
[0151]
According to the present embodiment, the second acoustic matching layer having low density, low acoustic impedance, and high thickness accuracy can be formed, so that the characteristics of the acoustic matching layer having a two-layer structure can be further improved. Therefore, by using the acoustic matching layer of the present embodiment, it is possible to obtain a highly reliable and stable ultrasonic transducer.
[0152]
(Seventh embodiment)
FIG. 8 is a sectional view of the piezoelectric vibrator of the ultrasonic transducer used in the ultrasonic flowmeter of the present invention. In this figure, a piezoelectric vibrator 10 for performing electric-ultrasonic mutual conversion is composed of a piezoelectric layer 2 and an acoustic matching layer 100. The piezoelectric layer 2 generates ultrasonic vibration, is made of a piezoelectric ceramic, a piezoelectric single crystal, or the like, is polarized in a thickness direction, and has electrodes on upper and lower surfaces. The acoustic matching layer 100 is for transmitting an ultrasonic wave to a gas or receiving an ultrasonic wave propagating through the gas, and the mechanical vibration of the piezoelectric layer 2 excited by the driving AC voltage causes external vibration. The medium has a function of efficiently radiating ultrasonic waves to the medium and arriving ultrasonic waves are efficiently converted to a voltage. The medium is formed using the above-described embodiment, and forms a transmitting and receiving surface of ultrasonic waves in the piezoelectric layer 2. And bonded to the outside of the case 1 by chemical bonding.
[0153]
Furthermore, since the thickness of the acoustic matching layer 100 is strictly defined by the thickness control unit 101, there is no surface unevenness.
[0154]
In the ultrasonic transducer configured as described above, when a burst signal voltage having an AC signal component having a frequency near the resonance frequency of the ultrasonic transducer is applied to the drive terminal, the piezoelectric vibrator 10 operates in the thickness vibration mode. And emits a burst of ultrasonic waves into a fluid such as a gas or a liquid.
[Brief description of the drawings]
[0155]
FIGS. 1A and 1B are cross-sectional views schematically showing a structure of an acoustic manufacturing layer according to an embodiment of the present invention.
FIG. 2 is a process diagram illustrating a method for manufacturing the ultrasonic transducer according to the first embodiment of the present invention.
FIG. 3 is a process diagram illustrating a method for manufacturing an ultrasonic transducer according to a second embodiment of the present invention.
FIG. 4 is a process chart illustrating a method for manufacturing an ultrasonic transducer according to a third embodiment of the present invention.
FIG. 5 is a process diagram illustrating a method for manufacturing an ultrasonic transducer according to a fourth embodiment of the present invention.
FIG. 6 is a process diagram illustrating a method for manufacturing an ultrasonic transducer according to a fifth embodiment of the present invention.
FIG. 7 is a process diagram illustrating a method for manufacturing an ultrasonic transducer according to a sixth embodiment of the present invention.
FIG. 8 is a sectional view of an ultrasonic transducer according to the present invention.
FIG. 9 is a block diagram schematically showing a configuration of an ultrasonic flowmeter using a conventional ultrasonic transducer.
FIG. 10 is a cross-sectional view schematically showing a configuration of a conventional ultrasonic wave receiver.
11A and 11B are diagrams schematically showing a configuration of an acoustic matching layer of a conventional ultrasonic wave receiver, where FIG. 11A is a cross-sectional view, and FIG. 11B is a top view. FIG.

Claims (24)

Acoustic matching layer containing dry gel powder. The density of the dry gel is not more 500 kg / m ³ or less, an average pore diameter is 100nm or less, the acoustic matching layer according to claim 1. The acoustic matching layer according to claim 1, wherein the average particle size of the powder of the dried gel is in a range of 1 μm or more and 100 μm or less. The acoustic matching layer according to claim 1, wherein the solid skeleton of the dried gel contains an inorganic oxide. The acoustic matching layer according to claim 3, wherein the inorganic oxide is silicon oxide or aluminum oxide. The acoustic matching layer according to any one of claims 1 to 5, wherein the acoustic matching layer contains 40% by mass or less of the heat binding polymer powder. The acoustic matching layer according to claim 6, wherein the powder of the heat binding polymer has an average particle diameter in a range of 0.1 µm or more and 50 µm or less. The acoustic matching layer according to any one of claims 1 to 7, wherein the acoustic impedance is in the range of 5 x 10 ⁴ kg / s-m ² or more and 20 x 10 ⁴ kg / s-m ² or less. The acoustic matching layer according to any one of claims 1 to 8, wherein a temperature change rate of the acoustic impedance in a range of 25C or more and 70C or less is -0.04% / C or less. The acoustic matching layer according to any one of claims 1 to 9, wherein the acoustic matching layer has a thickness of about one quarter of a wavelength λ of a sound wave propagating in the acoustic matching layer. An ultrasonic transducer comprising: a piezoelectric layer; and the acoustic matching layer according to claim 1 provided on the piezoelectric layer. The ultrasonic transducer according to claim 11, wherein the acoustic matching layer is directly bonded on the piezoelectric layer. Further comprising a case having an upper plate forming a recess enclosing the piezoelectric layer, and a bottom plate arranged to seal the space in the recess,
The piezoelectric layer is adhered to an inner surface of the upper plate of the case,
The ultrasonic transducer according to claim 11, wherein the acoustic matching layer is directly coupled to an upper surface of the upper plate so as to face the piezoelectric layer via the upper plate. A step of preparing a mixed powder of a dry gel powder and a heat binding polymer powder,
Pressing the mixed powder,
A method for manufacturing an acoustic matching layer, comprising: The step of preparing the mixed powder,
Providing the dried gel;
Preparing a powder of the heat-binding polymer,
Pulverizing while mixing the dried gel and the heat binding polymer powder,
The method for manufacturing an acoustic matching layer according to claim 14 , comprising: The method for manufacturing an acoustic matching layer according to claim 15 , wherein the step of pressure-forming the mixed powder includes a step of heating the mixed powder. A step of compression molding the mixed powder includes the step of controlling the thickness of the molded body of the mixed powder obtained by pressing a predetermined thickness, according to any of claims 14 to 16 Manufacturing method of acoustic matching layer. The step of press-molding the mixed powder,
Supplying a predetermined amount of the mixed powder on the lower molding surface,
Manufacturing method of the comprising the steps of: planarizing the top surface of the layer of the mixed powder which is supplied to the lower molding surface on forms, and acoustic matching layer according to any one of claims 14 17. A method for manufacturing an ultrasonic transducer including a piezoelectric layer and an acoustic matching layer provided on the piezoelectric layer,
A method of manufacturing an ultrasonic transducer, comprising a step of forming the acoustic matching layer by the method of any one of claims 14 to 17 . 20. The method according to claim 19 , wherein the acoustic matching layer is directly bonded on the piezoelectric layer. The ultrasonic transducer further comprises a case having a top plate which forms a recess for containing the piezoelectric layer, and a bottom plate arranged to seal the space within said recess,
20. The method according to claim 19 , wherein the acoustic matching layer is directly bonded to an upper surface of the upper plate of the case. A method for manufacturing an ultrasonic transducer including a piezoelectric layer and an acoustic matching layer provided on the piezoelectric layer,
The process of forming the acoustic matching layer comprises:
(A) a step of preparing a gel raw material liquid;
(B) providing a thickness regulating member having a predetermined height on a surface on which the acoustic matching layer is formed;
(C) applying the gel raw material liquid on the surface;
(D) making the thickness of the liquid layer formed by the gel raw material liquid provided on the surface substantially equal to the height of the thickness regulating member;
(E) a solidification step of forming a wet gel from the gel raw material liquid;
(F) a drying step of forming a dry gel by removing a solvent contained in the wet gel;
A method for manufacturing an ultrasonic transducer, comprising: The acoustic matching layer has a first acoustic matching layer disposed on the piezoelectric layer side, and a second acoustic matching layer provided on the first acoustic matching layer,
23. The method for manufacturing an ultrasonic transducer according to claim 22 , wherein a process of forming the second acoustic matching layer includes the steps (a) to (f). Height of the thickness regulating member is approximately one-quarter the wavelength of the acoustic wave propagating the corresponding acoustic matching layer lambda, according to any one of claims 22 or 23 of the ultrasonic transducer Production method.

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